Download SERVICE MANUAL SHIMANO NEXUS 8-SPEED HUB
Transcript
t English SHIMANO NEXUS 8-SPEED HUB SG-8R20 SERVICE MANUAL vol.2 Contents Disassembly of the Inter-8 hub • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 3 Assembly of the Inter-8 hub • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 10 Cassette Joint & Mesurement Tool • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 17 Spare parts list (SG-8R20 / BR-IM70-R / C J-8S20) • • • • • • • • • • • • • • • • • • • • • • 18 Spare parts list (SB-8S20) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 19 Spare parts list (CJ-8S40) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 20 Spare parts list (BL-IM60) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 21 Spare parts list (ST-8S20) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 22 Spare parts list (BL-IM65) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 23 2 Disassembly of the Inter-8 hub 1. Hold the two bevelled surfaces of the hub axle on the sprocket side in a vice. 2. Remove the lock nut for left hand cone with 14 X14mm spanners. Lock nut for left hand cone (Y-31Z 06020) 3. Remove the left hand cone. Left hand cone (Y-308 98070) 3 4. Remove the ball retainer P (3/16"X13). Ball retainer P (Y-34R 98070) 5. Remove the hub shell. 6. Remove the right hand dust cap. Right hand dust cap (Y-34R 98110) 7. Remove the stop ring with screwdriver. At this time, the stop ring come off with great force. Be careful of the safety using cloth and so on. Stop ring (Y-34R 79000) 4 8. Remove carrier unit and ring gear unit at the same time without tuning them to the left and right. 9. Remove the ring gear stop ring with a screwdriver. Ring gear stop ring (Y-34R 80000) Carrier unit (Y-34R 98020) Ring gear 1 (Y-34R 47000) Ring gear stop ring (Y-34R 80000) 5 10. Remove ball retainer O (3/16"X26). Ball retainer O (Y-34R 98030) 11. Then hold the axle unit upside down in a vice. 12. Remove the right hand lock nut with 17mm spanner. Right hand lock nut (Y-33Z 07020) 13. Remove stop washer. Stop washer (Y-34R 09000) 6 14. Remove lock washer. Lock washer (Y-34R 98090) 15. Remove driver plate. Driver plate (Y-34R 12000) 16. Support the driver by the vice. Set the tool and hit it with hammer untill right hand cone and axle unit is separate. If you try to disassemble the right hand cone without using this tool, the return spring in the axle unit may disengage. Set the tool into the groove so that the pawl A is on the surface of the tool. Tool TL-8S10 (Y-70800100) A 7 17. Remove right hand cone. Right hand cone (Y-34R 98080) 18. Remove ball retainer P (3/16"X13). Ball retainer P (Y-34R 98070) 19. Remove driver unit. Driver unit (Y-34R 98060) 20. Remove return spring. Return spring (Y-34R 21000) 8 21. Remove the clutch unit while turning it counterclockwise and fixing two pawls to two grooves as shown in the picture. Clutch unit (Y-34R 98050) 9 Assembly of the Inter-8 hub 1. When installing the clutch unit, align two pawls of the clutch unit with two grooves. After installing the clutch unit, turn it clockwise. Clutch unit (Y-34R 98050) 2. 3. Install the return spring while aligning it with the blue line shown in the picture. Be careful not to install it upside-down. (The bigger part is downside.) Return spring (Y-34R 21000) Set the drive unit while align the shallow side of groove of driver unit and wider portion of swelling on the clutch unit. Set drive unit while turn it counterclockwise. 4. Install the ball retainer P (3/16"X13). Ball retainer P (Y-34R 98070) GREASE (Y-041 20600) 10 5. When installing the right hand cone, adjust two serration as shown in the picture. Set the tool and hit it untill it stops. Right hand cone (Y-34R 98080) Tool TL-8S20 (Y-70800200) Make sure that seal is installed equally, and install right hand cone properly. seal 6. Install the driver plate. Be careful of the setting direction asshown in the picture. Driver plate (Y-34R 12000) 7. Install lock washer. Lock washer (Y-34R 98090) 11 8. When installing the stop washer, align two pawls of the stop washer with the grooves of lock washer. Stop washer (Y-34R 09000) 9. Install the right hand lock nut (3.4mm) with 17mm spanner. Take care that the stop washer does not turn. Tightening torque: 25 - 30 N·m {218 - 261 in.lbs} Right hand lock nut (Y-33Z 07020) 10. Then hold the axle unit upside down in a vice. 11. Install the ball retainer O (3/16"X26) while pressing in pawl on the driver & axle unit. Ball retainer O (Y-34R 98030) GREASE (Y-041 20600) 12 12. How to install the carrier unit and ring gear. (Without any tools) Align three marks of the ring gear with three grooves as shown in the picture. Carrier unit (Y-34R 98020) GREASE (Y-041 20600) Ring gear 1 (Y-34R 47000) Tool TL-8S30 (Y-70800300) (With tool) Align the grooves of the tool with the marks of the ring gear. GREASE (Y-041 20600) Install the ring gear stop ring with a screwdriver. Ring gear stop ring (Y-34R 80000) 13 13. Aligh the swelling of ring gear/carrier unit and the groove of axle unit. After installing ring gear and carrier unit, turn units firmly and check that pawls are in their position. GREASE (Y-041 20600) To proceed this section, it is important to set four pawls in their position. Use flat blade screwdriver to push pawls as shown in the instruction then install ring gear and carrier unit slowlly. pawls No good Pawls are not in their proper position 14 14. Insert the stop ring. Stop ring (Y-34R 79000) 15. Install the hub shell unit while turning it counterclockwise. 16. Insert ball retainer P (3/16"X13) in the hub shell. Ball retainer P (Y-34R 98070) GREASE (Y-041 20600) 17. Install the left hand cone. Left hand cone (Y-308 98070) 15 18. 19. Install the lock nut for left hand cone with 14X14mm spanners. Adjust the hub with the left hand cone so that there is a small amount of play. This play should disappear after tightening the locknut. Tightening torque: 25 - 30 N·m {218 - 261 in.lbs} Lock nut for left hand cone (Y-31Z 06020) Install the right hand dust cap. Make sure that the seal of dust cap also installed correctly. Right hand dust cap (Y-34R 98110) GREASE (Y-041 20600) This completes assembly of the Inter-8 hub. 16 Cassette Joint CJ-8S20 for 8 speed CJ-NX10 for 7 speed CJ-8S40 for 8 speed CJ-7S40 for 7 speed CJ-8S20 CJ-NX10 Mesurement Tool 101mm TL-CJ10 for CJ-8S20 101mm TL-CJ40 for CJ-8S20 124mm TL-CJ40 for CJ-8S40 17 Spare parts list SHIMANO NEXUS 8-SPEED HUB w/Hi-Power Roller Brake 22 20 26 MIN JA 28 29 11 GREA 23 04 30 31 42 33 32 34 35 36 18 17 SE 24 SG-8R20 JAPAN VIA TL-8S30 RELEA SE 25 CJ-8S20 Internal Assembly N 2 7L PA Grease 41 Inter-M Brake 1 2Nm 17 19 Inter-8 Hub PE-LD SG-8R20 BR-IM70-R 21 37 1 For w/o Roller Brake (SG-8R20-VS) 2 3 4 5 6 7 27 8 9 10 38 TL-8S20 11 12 13 14 15 16 39 2 TL-8S10 40 Q'TY ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 * 32 33 34 35 36 37 * 38 * 39 * 40 41 42 SHIMANO CODE NO. Y-34R 98010 Y-34R 79000 Y-34R 98020 Y-34R 47000 Y-34R 80000 Y-34R 98030 Y-34R 98040 Y-34R 98050 Y-34R 21000 Y-34R 98060 Y-34R 98070 Y-34R 98080 Y-34R 12000 Y-34R 98090 Y-34R 09000 Y-33Z 07020 Y-314 14010 Y-33Z 20500 Y-33M39600 Y-33M39700 Y-33M39510 Y-33M39610 Y-33M39710 Y-75V 13041 Y-75M98050 Y-33F 98090 Y-75M98060 Y-33F 98100 Y-75E 98010 Y-75F 11000 Y-75F 98020 Y-75E 98020 Y-75T 05000 Y-34R 98100 Y-31Z 06020 Y-308 98070 Y-34R 98110 Y-322 03220 Y-322 03420 Y-322 03520 Y-322 03620 Y-330 60000 Y-330 60100 Y-321 20100 Y-74Y 98120 Y-74Y 18000 Y-74Y 98130 Y-33Z 98020 Y-74Y 98030 Y-708 00300 Y-708 00200 Y-708 00100 Y-041 20600 Y-041 20400 Y-041 40020 DESCRIPTION Internal Assembly (Axle Length 184 mm) Stop Ring ( 12 mm) Carrier Unit Ring Gear 1 Ring Gear 1 Stop Ring Ball Retainer O (3/16" x 26) Hub Axle Unit (Axle Length 184 mm) Clutch Unit Return Spring A Driver Unit Ball Retainer P (3/16" x 13) Right Hand Cone w/Seal Driver Plate Lock Washer Stop Washer Right Hand Lock Nut (3.4 mm) Cap Nut (3/8") Non-turn Washer 5R (Yellow) Non-turn Washer 6R (Silver) Non-turn Washer 7R (Black) Non-turn Washer 5L (Brown) Non-turn Washer 6L (White) Non-turn Washer 7L (Gray) Brake Unit Fixing Nut (7.2 mm) Brake Arm Clip Unit ( 15 mm) Brake Arm Clip Unit (5/8") Brake Arm Clip Unit (11/16") Brake Arm Clip Unit (3/4") Brake Cable Adjusting Bolt Unit Grease Hole Cap Inner Cable Fixing Bolt & Nut Link Unit Seal Ring for Brake Left Hand Dust Cap Unit Lock Nut for Left Hand Cone Left Hand Cone w/Dust Cap Right Hand Dust Cap A w/Seal Sprocket Wheel 16T (Silver) Sprocket Wheel 18T (Silver) Sprocket Wheel 19T (Silver) Sprocket Wheel 20T (Silver) Sprocket Wheel 21T (Silver) Sprocket Wheel 22T (Silver) Snap Ring C CJ-8S20 Cassette Joint Unit Driver Cap CJ-8S20 Cassette Joint Cassette Joint Fixing Ring Inner Cable Fixing Bolt Unit TL-8S30 Carrier Unit Tool TL-8S20 Right Hand Cone Installation Tool TL-8S10 Right Hand Cone Removal Tool Internal Hub Grease (Net. 100 g) Roller Brake Grease (Net. 100 g) Roller Brake Grease (Net. 10 g) IL /SG Printed in Japan 0306-2236A 18 Spare parts list SHIMANO NEXUS Revo-Shift Lever SB-8S20 For 8-Speed 8 2 V 9 C R 3 4 1 5 7 6 11 10 12 13 1.2mm 2000m m x100pc SI-SP36B s SERVICE INSTRUCTIO SI-SP40 useread Before use. correct NS Outer Casing carefully, and follow them for these instructions inner for an designed be used for is specially it can not Notes: casing diameter This outer1.1 mm in diameter; mm in cable of cable of 1.2 an inner in diameter MARK cable of 1.1 mm inner packaging i in bulk s grease outer casingmust install will resu You SIS^SP36 resistance internally. Shimano or cable is not greased outer casing ( sold separ casing. nside the shifting quality. outer cap the outer lt in poor SIS-SP36 sealed side of the derailleur Install the rear atery )to NO MA SHI ON TAL ATI TO EGR INT 14 E BL R CA INNE SHIM TOTAANO INTE L GRA TION INN ER CAB LE 1.2 mm 2000 mm (100 pcs.) Q'TY ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SHIMANO CODE NO. Y-6J3 98010 Y-6J3 98030 Y-8TS 98010 Y-8S8 98010 Y-89E 05010 Y-61W98030 Y-8SB 10000 Y-6J3 04000 Y-61X 14010 Y-600 98510 Y-6Z2 98100 Y-620 98030 Y-6Z2 98010 Y-6Z1 90010 10 m / 32.8 ft. 1.2 mm (100 pcs.) DESCRIPTION Indicator Cover & Fixing Screws (M3 x 5) Upper Cover & Fixing Screw (M3 x 5) R.H. Adjustment Block & Screw Brake Cable Adjusting Bolt (M10 x 19) & Nut Reach Adjusting Screw (M4 x 10.8) Cable Adjusting Bolt Unit Clamp Bolt (M6 x 14.8) Shift Actuator (Black) Half Grip ( 22.2 mm / Black) Inner Cable Box (Stainless / 100 pcs.) for Shift SIS-SP40 Outer Casing (Black) for Shift Inner End Caps ( 1.2 mm / 100 pcs.) SIS-SP40 Sealed Outer Caps (Revo-Shift Lever Side / Black / 6 mm / 100 pcs.) SIS-SP40 Sealed Outer Cap (Cassette Joint Side / Silver / 6 mm) IL/SB Printed in Japan 0302-2238 19 Spare parts list SHIMANO NEXUS Cassette Joint CJ-8S40 1 2 3 4 40 -8S CJ AN P JA 8 9 7 5 Q'TY ITEM NO. 1 2 3 4 5 6 7 8 9 SHIMANO CODE NO. Y-74Y 98160 Y-74Y 27000 Y-74Y 28000 Y-74Y 30200 Y-74Y 98140 Y-33Z 98020 Y-74Y 98150 Y-74Y 18000 Y-74Y 98030 6 DESCRIPTION Outer Casing Holder Unit Rubber Cover Outer Casing Holder Rubber Bellows Cassette Joint Unit Cassette Joint Fixing Ring Cassette Joint Driver Cap Inner Cable Fixing Bolt Unit IL/CJ Printed in Japan 0302-2237 20 Spare parts list SHIMANO NEXUS Brake Lever BL-IM60 For Left Hand / 4-Finger 5 1 2 4 Q'TY ITEM NO. 1 2 3 4 5 SHIMANO CODE NO. Y-8TS 98020 Y-8S8 98010 Y-89E 05010 Y-8SB 10000 Y-89M08010 3 DESCRIPTION L.H. Adjustment Block & Screw Cable Adjusting Bolt (M10 x 19) & Nut Reach Adjusting Screw (M4 x 10.8) Clamp Bolt (M6 x 14.8) Grip ( 22.2 mm / Black) IL/BL Printed in Japan 0302-2239 21 Spare parts list SHIMANO NEXUS Tap-Fire Lever ST-8S20 For 8-Speed 11 1.2mm 2000m m x100pc s 1 NO MA SHI ON E TAL ATI BL EGR CA R INNE TO INT SHIM TOTAANO INTE L GRA TION INN ER CAB LE 1.2 mm 2000 mm (100 pcs.) 7 12 2 3 SI-SP36B SERVICE INSTRUCTIO SI-SP40 useread Before use. correct NS Outer these instructions Casing carefully, and follow them for inner for an designed be used for is specially it can not Notes: casing diameter This outer1.1 mm in diameter; mm in cable of cable of 1.2 an inner in diameter MARK cable of 1.1 mm inner packaging i in bulk s grease outer casingmust install will resu You SIS^SP36 resistance internally. Shimano or cable is not greased outer casing ( sold separ casing. nside the shifting quality. outer cap the outer lt in poor SIS-SP36 sealed side of the derailleur Install the rear atery )to 4 11 8 8 10 m / 32.8 ft. 13 6 5 9 1.2 mm (100 pcs.) 10 Q'TY ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 SHIMANO CODE NO. Y-6JB 98010 Y-8TS 98010 Y-6JB 98030 Y-6JB 98040 Y-61W98030 Y-6JB 98050 Y-6JB 98060 Y-8SB 10000 Y-6JB 98070 Y-6JB 98080 Y-600 98510 Y-6Z2 98100 Y-620 98030 Y-6Z2 98010 Y-6Z1 90010 14 15 DESCRIPTION Indicator Unit R.H. Adjustment Block & Screw Reach Adjusting Screw (M4 x 47) w/Cap Brake Cable Adjusting Bolt (M10 x 19) & Nut Cable Adjusting Bolt Unit Cable Cover & Cover Fixing Screw (M2.5 x 4) Tap Cover & Fixing Screw (M3 x 4) Clamp Bolt (M6 x 14.8) Lower Cover & Cover Fixing Screw (M3 x 12) Main Lever Cover & Fixing Screw (M3 x 4) Inner Cable Box (Stainless / 100 pcs.) for Shift SIS-SP40 Outer Casing (Black) for Shift Inner End Caps ( 1.2 mm / 100 pcs.) SIS-SP40 Sealed Outer Caps (Shift Lever Side / Black / 6 mm / 100 pcs.) SIS-SP40 Sealed Outer Cap (Cassette Joint Side / Silver / 6 mm) IL/ST Printed in Japan 0305-2244 22 Spare parts list SHIMANO NEXUS Brake Lever BL-IM65 For Left Hand / 3-Finger 5 1 2 4 Q'TY ITEM NO. 1 2 3 4 5 SHIMANO CODE NO. Y-8TS 98020 Y-6JB 98040 Y-89E 05010 Y-8SB 10000 Y-89M08010 3 DESCRIPTION L.H. Adjustment Block & Screw Cable Adjusting Bolt (M10 x 19) & Nut Reach Adjusting Screw (M4 x 10.8) Clamp Bolt (M6 x 14.8) Grip ( 22.2 mm / Black) IL/BL Printed in Japan 0305-2245 23 SHIMANO AMERICAN CORPORATION One Holland, Irvine, California 92618, U.S.A. Phone: +1-949-951-5003 Fax: +1-949-768-0920 Specifications are subject to change for improvement without notice. This publication is printed on recycled paper. MA34RB © Jan. 2004 Shimano Inc. UCI official neutral technical support t